xen pluseecat xel

Model Ic Ip Vac

XEL-230-18 6 18 100-240

XEL-230-36 12 36 100-240

XEL-230-40 20 40 100-240

Copley Controls, 20 Dan Road, Canton, MA 02021, USA Tel: 781-828-8090 Fax: 781-828-6547 P/N 16-01637 Rev 02 of 28

Xenus PLUS

EtherCAT XEL

DESCRIPTIONXenus Plus set new levels of performance, connectivity, and flexibility. Ethernet based EtherCAT operates in CAN application layer over EtherCAT (CoE) mode. A wide range of absolute interfaces are built-in including EnDat, and BiSS.

High resolution A/D converters ensure optimal current loop performance. Both isolated and high-speed non-isolated I/O are provided. For safety critical applications, redundant power stage enable inputs can be employed.

Add -R for resolver feedback option.

Control Modes • Cyclic Synchronous Position-Velocity-Torque (CSP, CSV, CST) • Profile Position-Velocity-Torque, Interpolated Position, Homing • Camming, Gearing • Indexer

Command Interface • CAN application layer over EtherCAT (CoE) • ASCII and discrete I/O • Stepper commands • ±10V position/velocity/torque (2 inputs) • PWM velocity/torque command • Master encoder (Gearing/Camming)

Communications • EtherCAT • RS-232

Accessories • External regen resistors • External edge filter

Feedback • Digital quad A/B encoder Analog sin/cos incremental Panasonic Incremental A Format • SSI, EnDat, Absolute A Tamagawa & Panasonic Absolute A Sanyo Denki Absolute A, BiSS,BiSS • Aux. encoder / encoder out • Resolver option • Digital Halls

Motor Torque Off • Two active inputs enable power stage • One output confirms power stage status

I/O Digital • 15 inputs, 6 outputs

I/O Analog • 2, 16-bit inputs • 1, 12-bit input • 1, 12-bit output

Dimensions: in [mm] • 7.92 x 5.51 x 2.31 in (201.2 x 139.9 x 58.7 mm)

DIGITAL SERVO DRIVE FOR BRUSH/BRUSHLESS MOTORS


Xenus PLUS

EtherCAT XELGENERAL SPECIFICATIONS Test conditions: Wye connected load: 2 mH line-line. Ambient temperature = 25 °C. Power input = 230 Vac, 60 Hz, 1 Ø

MODEL XEL-230-18 XEL-230-36 XEL-230-40OUTPUT CURRENT

Peak Current 18 (12.7) 36 (25.5) 40 (28.3) Adc (Arms, sinusoidal) Peak time 1 1 1 s Continuous current (Note 1) 6 (4.24) 12 (8.5) 20 (14.1) Adc (Arms, sinusoidal)INPUT POWER Mains voltage, phase, frequency 100~240 Vac, ±10%, 1Ø or 3Ø, 47~63 Hz Maximum Mains Current, 1Ø (Note 3) 10.1 20.0 20.0 Arms Maximum Mains current, 3Ø (Note 3) 6.4 10.4 15.4 Arms +24 Vdc Control power +20 to +32 Vdc, 500 mA max Required for operationDIGITAL CONTROL Digital Control Loops Current, velocity, position. 100% digital loop control Sampling rate (time) Current loop: 16 kHz (62.5 µs), Velocity & position loops: 4 kHz (250 µs) Bus voltage compensation Changes in bus or mains voltage do not affect bandwidth Minimum load inductance 200 µH line-lineCOMMAND INPUTS Distributed Control Mode

CAN application layer over EtherCAT (CoE) Cyclic Synchronous Position-Velocity-Torque, Profile Position-Velocity-Torque, Interpolated Position, Homing Stand-alone mode Analog torque, velocity, position reference ±10 Vdc, 16-bit resolution Dedicated differential analog input Digital position reference Pulse/Direction, CW/CCW Stepper commands (2 MHz maximum rate) Quad A/B Encoder 2 M line/sec, 8 Mcount/sec (after quadrature) Digital torque & velocity reference PWM , Polarity PWM = 0% - 100%, Polarity = 1/0 PWM 50% PWM = 50% ±50%, no polarity signal required PWM frequency range 1 kHz minimum, 100 kHz maximum PWM minimum pulse width 220 ns Indexing Up to 32 programs can be launched from inputs or ASCII commands. Camming Up to 10 CAM tables can be stored in flash memoryDIGITAL INPUTS Number 14 [IN1,2,15] Non-isolated Schmitt trigger, 1 µs RC filter, 24 Vdc max, Vin-HI >= 3.15 Vdc, Vin-LO <= 1.13 Vdc 10 kΩ programmable per input to pull-up to +5 Vdc or pull-down to ground [IN3~6] Non-isolated line receiver, 100 ns RC filter, +12 Vdc max, programmable as 4 single-ended, or 2 differential Single-ended: [IN3,4] or [IN5,6]: Vin-LO <= 2.3 Vdc, Vin-HI >= 2.7 Vdc Differential: [IN3/4] or [IN5/6]: Vin-LO <= -200 mVdc, Vin-HI >= 200 mVdc [IN7~14] Digital, opto-isolated, single-ended, ±15~30 Vdc compatible, bi-polar, 2 groups of 4 with common return for each group Rated impulse ≥ 800 V, Vin-LO ≤ 6.0 Vdc, Vin-HI ≥ 10.0 Vdc, Input current ±3.6 mA @ ±24 Vdc, typicalANALOG INPUTS Number 3 [AIN1~2] Differential, ±10 Vdc, 5 kΩ input impedance, 16-bit resolution [AIN3] Single-ended, motor temperature sensor, 4.99 kΩ pulled-up to +5 Vdc, 12-bit resolutionDIGITAL OUTPUTS Number 6 [OUT1~2] Current-sinking MOSFET with 1 kΩ pullup to +5 Vdc through diode 1 Adc max, +40 Vdc max; external flyback diode required if driving inductive loads [OUT3] High-speed CMOS buffer, ±32 mA [OUT4~5] Opto-isolated Darlingtons with 36V Zener flyback diodes, 20 mA max [OUT6] Motor brake control: opto-isolated, 1 Adc max, current-sinking with flyback diode to +24 Vdc (J4-3)ANALOG OUTPUT Number, type 1, ±5 Vdc single-ended, 12-bit resolutionMULTI-MODE ENCODER PORT As Input Secondary digital quadrature encoder (A, /A, B, /B, X, /X), no terminating resistors 18 M-counts/sec, post-quadrature (4.5 M-lines/sec) RS-422/RS-485 line receiver with fault detection for open/shorted inputs, or low signal amplitude As Output Quadrature encoder emulation with programmable resolution to 4096 lines (65,536 counts) per rev from analog sin/cos encoders or resolvers. Buffered signals from digital quad A/B/X primary encoder A, /A, B, /B, X, /X, from MAX3032 differential line driverRS-232 PORT Signals RxD, TxD, Gnd in 6-position, 4-contact RJ-11 style modular connector Mode Full-duplex, DTE serial communication port for drive setup and control, 9,600 to 115,200 Baud Protocol Binary and ASCII formatsETHERCAT PORTS Format Dual RJ-45 receptacles, 100BASE-TX Protocol EtherCAT, CAN application layer over EtherCAT (CoE)STATUS INDICATORS Drive Status Bicolor LED, drive status indicated by color, and blinking or non-blinking condition NET Status Bicolor LED, status of EtherCAT bus indicated by color and blink codes to CAN Indicator Specification 303-35V OUTPUT Two independent 5 Vdc @ 400 mA outputs, thermal and short-circuit protectedNOTES:

1. Heatsinking and/or forced-air cooling is required for the continuous output power rating2. Brake[OUT6] is programmable as motor brake, or as general purpose digital output3. The actual mains current is dependent on the mains voltage, number of phases, and motor load and operating conditions. The Maximum Mains Currents shown above

occur when the drive is operating from the maximum input voltage and is producing the rated continuous output current at the maximum output voltage.


Xenus PLUS

EtherCAT XELREGENERATION

Operation Internal solid-state switch drives external regen resistor (see Ordering Guide for types) Cut-In Voltage +HV > 390 Vdc Regen output is on, (optional external) regen resistor is dissipating energy Drop-Out Voltage +HV < 380 Vdc Regen output is off, (optional external) regen resistor not dissipating energy Tolerance ±2 Vdc For either Cut-In or Drop-Out voltagePROTECTIONS AC Mains Loss Loss of mains power between L1 & L2 is detected HV Overvoltage +HV > 400 Vdc Drive PWM outputs turn off until +HV is less than overvoltage HV Undervoltage +HV < 60 Vdc Drive PWM outputs turn off until +HV is greater than undervoltage Drive over temperature IGBT > 80 °C ±3 °C Drive PWM outputs turn off until IGBT temperature is below threshold Short circuits Motors: Output to output, output to ground, output to HV, internal PWM bridge faults Regen: Regen+ to ground, Regen- to HV I2T Current limiting Programmable: continuous current, peak current, peak time Motor over temperature Programmable input to disable drive when voltage is above or below a set point 0~5 Vdc Feedback power loss Fault occurs if feedback is removed or +5V Out1 is <85% of normalMECHANICAL & ENVIRONMENTAL Size 7.92 x 5.51 x 2.31 in (201.2 x 139.9 x 58.7 mm) Weight 3.0 lb (1.36 kg) for drive without heatsink 3.1 lb (1.40 kg) for XEL-HS heatsink, 1.86 lb (0.84 kg) for XEL-HL heatsink Ambient temperature 0 to +45 °C operating, -40 to +85 °C storage Humidity 0% to 95%, non-condensing Contaminants Pollution degree 2 Vibration 2 g peak, 10~500 Hz (sine), IEC60068-2-6 Shock 10 g, 10 ms, half-sine pulse, IEC60068-2-27 Environment IEC68-2: 1990 Cooling Heat sink and/or forced air cooling required for continuous power output

AGENCY STANDARDS CONFORMANCEIn accordance with EC Directive 2014/30/EU (EMC Directive) EN 55011: 2009/A1:2010 CISPR 11:2009/A1:2010

Industrial, Scientific, and Medical (ISM) Radio Frequency Equipment – Electromagnetic Disturbance Characteristics – Limits and Methods of Measurement Group 1, Class A

EN 61000-6-1: 2007 Electromagnetic Compatibility (EMC) – Part 6-1: Generic Standards – Immunity for residential, Commercial and Light-industrial Environments

In accordance with EC Directive 2014/35/EU (Low Voltage Directive) IEC 61010-1:2010 Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory UseUnderwriters Laboratory Standards UL 61010-1, 3rd Ed.: 2012-05 Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory Use UL File Number E168959Restriction of the Use of Certain Hazardous Substances (RoHS) Directive 2011/65/EU (RoHS II)

FEEDBACK SPECIFICATIONSDIGITAL QUAD A/B ENCODER Type Quadrature, differential line driver outputs Signals A, /A, B, /B, (X, /X, index signals optional) RS-422/RS-485 line receivers with fault detection for open/shorted inputs, or low signal amplitude Frequency 5 MHz line frequency, 20 MHz quadrature count frequencyANALOG ENCODER Type Sin/cos/index, differential line driver outputs, 0.5 Vpeak-peak (1.0 Vpeak-peak differential) centered about 2.5 Vdc typical. Common-mode voltage 0.25 to 3.75 Vdc Signals Sin(+), sin(-), cos(+), cos(-), index(+), index(-) Frequency 230kHz maximum line (cycle) frequency Interpolation 10 bits/cycle (1024 counts/cycle)DIGITAL HALLS Type Digital, single-ended, 120° electrical phase difference Signals U, V, W Inputs 10 kΩ pullups to +5 Vdc, 1 µs RC filter to Schmitt trigger invertersMULTI-MODE ENCODER PORT As Input Secondary digital quadrature encoder (A, /A, B, /B, X, /X), no terminating resistors 18 M-counts/sec, post-quadrature (4.5 M-lines/sec) RS-422/RS-485 line receiver with fault detection for open/shorted inputs, or low signal amplitude As Emulated Output Quadrature encoder emulation with programmable resolution to 4096 lines (65,536 counts) per rev from analog sin/cos encoders or resolvers. A, /A, B, /B, X, /X, from MAX3032 differential line driver As Buffered Output Digital encoder feedback signals from primary digital encoder are buffered by MAX3032 line driverRESOLVER (-R OPTION) Type Brushless, single-speed, 1:1 to 2:1 programmable transformation ratio Resolution 14 bits (equivalent to a 4096 line quadrature encoder) Reference frequency 8.0 kHz Reference voltage 2.8 Vrms, auto-adjustable by the drive to maximize feedback Reference maximum current 100 mA Maximum RPM 10,000+ENCODER POWER SUPPLIES Number 2 Ratings +5 Vdc @ 400 mA from +5V Out1 on J8-20 and +5V Out2 on J10-6, J10-17 Protection Thermal and short-circuits to ground Encoder power developed from +24 Vdc so position information is not lost when AC mains power is removed

16-01637 Document Revision History

Revision Date Remarks

00 March 20, 2017 Initial released version

01 June 21, 2019 Change Safe Torque Off to Motor Torque Off

02 June 25, 2019 Remove green leaf and CE logo from page headers

139.885.51

2.31 58.67

5.72 145.35

1.00 25.40

4.83.19

7.92 201.17

191.527.54

19.18.76.31 7.92

32.691.29

5.12

6.12

130.07

191.527.54

201.177.92

4.83.19

TYP.094 2.37

76.203.00

R

.24.190 4.83

LINKLINK ACT

INOUT

STA

T

AM

P J7

ACT

Dev

ID


Xenus PLUS

EtherCAT XEL

Chassis Grounding: For CE compliance and machine safety an electrically conductive grounding tab is provided. This connects to the heatplate and to frame ground.

DIMENSIONS

Chassis grounding

tab

Units: Inches (mm)

MOTOR TORQUE OFF Inputs 2 two-terminal: MTO-1(+), MTO-1(-), MTO-2(+), MTO-2(-) Type Opto-isolators, 24V compatible Output 1 two-terminal: MTO-LED(+), MTO-LED(-) 24V compatible

SPECIFICATIONS (CONT’D)

Note!When you see this marker, it’s for hot tips or best practices that will help you get the best results when using Copley Controls products.

S1 S2

Hex Dec

0 0 0

1 16 1

2 32 2

3 48 3

4 64 4

5 80 5

6 96 6

7 112 7

8 128 8

9 144 9

A 160 10

B 176 11

C 192 12

D 208 13

E 224 14

F 240 15

16

18

18


Xenus PLUS

EtherCAT XEL

PIN SIGNAL

6 RX-

3 RX+

2 TX-

1 TX+

J7: EtherCAT PORTSRJ-45 receptacles, 8 position, 4 contact

ETHERCAT COMMUNICATIONSEtherCAT is the open, real-time Ethernet network developed by Beckhoff based on the widely used 100BASE-TX cabling system. EtherCAT enables high-

speed control of multiple axes while maintaining tight synchronization of clocks in the nodes. Data protocol is CAN application layer over EtherCAT (CoE) based on DSP-402 for motion control devices. More information on EtherCAT can be found on this web-site: http://ethercat.org/default.htm

ETHERCAT CONNECTIONSDual RJ-45 sockets accept standard Ethernet cables. The IN port connects to a master, or to the OUT port of a device that is ‘upstream’, between the Xenus and the master. The OUT port connects to ‘downstream’ nodes. If Xenus is the last node on a network, only the IN port is used. No terminator is required on the OUT port.

STAT LEDA bi-color LED (NET) indicates the status of the EtherCAT state machine and occurrence of errors. Green and red colors alternate: Green = RUN, Red = ERRORRUN (green) ERROR (red) Off = INITIALIZATION Off = No error Blinking = PRE-OPERATIONAL Blinking = Invalid configuration (note 1) Single Flash = SAFE-OPERATIONAL Single Flash = Local error (note 2) On = OPERATIONAL Double Flash = Watchdog timeout (note 3)Notes:1) A change of state commanded by the master is not possible or is illegal 2) This indicates that the slave has initiated a change of state by itself in response to an error 3) The EtherCAT watchdog timer has timed-out

ETHERCAT LINK & ACTIVITY LEDS (ON J7)These LEDs show the state of the physical link and activity on the linkA green LED indicates the state of the EtherCAT network:LED Link Activity Condition ON Yes No Port Open Flickering Yes Yes Port Open with activity Off No (N/A) Port Closed

J6: RS-232 PORTRJ-12 receptacle, 6 position, 4 contact

AMP

STAT

IN (A)

OUT (B)

LINK (green)

LINK (green)

ACT (yellow)

ACT (yellow)

EtherCAT Device ID Switch

Decimal values ---->

EtherCAT DEVICE IDIn an EtherCAT network, slaves are automatically assigned fixed addresses based on their position on the bus. But when the device must have a positive identification that is independent of cabling, a Device ID is needed. In the XEL, this is provided by two 16-position rotary switches with hexadecimal encoding. These can set the Device ID of the drive from 0x01~0xFF (1~255 decimal). The chart shows the decimal values of the hex settings of each switch.Example 1: Find the switch settings for decimal Device ID 107:1) Find the highest number under S1 that is less than 107 and set S1 to the hex value in

the same row: 96 < 107 and 112 > 107, so S1 = 96 = Hex 6

2) Subtract 96 from the desired Device ID to get the decimal value of switch S2 and set S2 to the Hex value in the same row: S2 = (107 - 96) = 11 = Hex B

S1 S2

AMP LEDA bi-color LED gives the state of the drive. Colors do not alternate, and can be solid ON or blinking. When mul-tiple conditions occur, only the top-most condition will be displayed. When that condition is cleared the next one below will shown.

1) Red/Blinking = Latching fault. Operation will not resume until drive is Reset. 2) Red/Solid = Transient fault condition. Drive will resume operation when the condition causing the fault is removed. 3) Green/Double-Blinking = Torque Off circuit active, drive outputs are Torque Off 4) Green/Slow-Blinking = Drive OK but NOT-enabled. Will run when enabled. 5) Green/Fast-Blinking = Positive or Negative limit switch active. Drive will only move in direction not inhibited by limit switch. 7) Green/Solid = Drive OK and enabled. Will run in response to reference inputs or EtherCAT commands.Latching FaultsDefault Optional (programmable) • Short circuit (Internal or external) • Over-voltage • Drive over-temperature • Under-voltage • Motor over-temperature • Motor Phasing Error • Feedback Error • Command Input Fault • Following Error

COMMUNICATIONS

PIN SIGNAL

2 RxD

3,4 Gnd

5 Txd

6

9

1

5

3 2TxD RxD

RJ-11on

ServoDrive

RJ-11 cable6P6CStraight-wired

5 3Gnd Gnd

RxD TxD2 5

D-Sub 9F

Dsub-9Fto RJ11Adapter

16

16


Xenus PLUS

EtherCAT XEL

ASCII COMMUNICATIONSThe Copley ASCII Interface is a set of ASCII format commands that can be used to operate and monitor Copley Controls Accelnet, Stepnet, and Xenus series amplifiers over an RS-232 serial connection. For instance, after basic amplifier configuration values have been programmed using CME 2, a control program can use the ASCII Interface to:• Enable the amplifier in Programmed Position mode.• Home the axis.• Issue a series of move commands while monitoring position, velocity, and other run-time variables.The Baud rate defaults to 9,600 after power-on or reset and is programmable up to 115,200 thereafter.Sending a break character will reset the Baud rate to 9,600.

Additional information can be found in the ASCII Programmers Guide on the Copley website:http://www.copleycontrols.com/Motion/pdf/ASCII_ProgrammersGuide.pdf

J6: RS-232 PORTRJ-12 receptacle, 6 position, 4 contact

STAT

AMP

Don’t forget to order a Serial Cable Kit SER-CK when placing your order for an XEL!

SER-CK SERIAL CABLE KITThe SER-CK provides connectivity between a D-Sub 9 male connector and the RJ-11 connector on the XEL. It includes an adapter that plugs into the COM1 (or other) port of a PC and uses common modular cable to connect to the XEL. The connections are shown in the diagram below.

RS-232 COMMUNICATIONSXEL is configured via a three-wire, full-duplex DTE RS-232 port that operates from 9600 to 115,200 Baud, 8 bits, no parity, and one stop bit. Signal format is full-duplex, 3-wire, DTE using RxD, TxD, and Gnd. Connections to the XEL RS-232 port are through J7, an RJ-11 connector. The XEL Serial Cable Kit (SER-CK) contains a modular cable, and an adapter that connects to a 9-pin, Sub-D serial port connector (COM1, COM2, etc.) on PC’s and compatibles.

PIN SIGNAL PIN SIGNAL

1 Frame Gnd 6 MTO-LED(+)

2 MTO-1(+) 7 MTO-LED(-)

3 MTO-1(-) 8 24 Vdc Common

4 MTO-2(+) 9 +24 Vdc Output

5 MTO-2(-)

16

95

2-93-45-8

Frame Ground

J5

4.99k

5.1V

+HV

High Side PWM

Low Side PWM MotorOuputs

4.99k

4.99k

5.1V

MTO-1

ENH

MTO-2

ENL

DIAG-ON

36V

10+V

4.99k

MTO-LED(+)

MTO-2(-)

MTO-1(+)

Channel 1

Channel 2

Xenus PlusMTOMuting

Connections

MTO-1(-)

MTO-2(+)

MTO-LED(-)

2

3

1

4

5

6

7

+24V OutputFrom 24V input on J4-39

Signal ground8


Xenus PLUS

EtherCAT XELDESCRIPTIONThe XEL has a safety feature that is designed to provide the Motor Torque Off (MTO) function as defined in IEC 61800-5-2. Two opto-couplers are provided which, when de-energized, prevent the upper and lower devices in the PWM outputs from being operated by the digital control core. This provides a positive OFF capability that cannot be overridden by the control firmware, or associated hardware components. When the opto-couplers are activated (current is flowing in the input diodes), the control core will be able to control the on/off state of the PWM outputs.

FUNCTIONAL DIAGRAMIn order for the PWM outputs of the XEL to be activated, current must be flowing through both opto-couplers that are connected to the MTO-1 and MTO-2 terminals of J5, and the drive must be in an ENABLED state. The LED outputs on J5 connect an opto-coupler to an external LED and will conduct current through the LED to light it whenever the PWM outputs can be activated, or the drive is in a diagnostic state. When the LED opto-coupler is OFF, the drive is in a Motor Torque Off state and the PWM outputs cannot be activated to drive a motor.

MTO MUTINGThe diagram below shows connections that will energize both MTO-1 and MTO-2 opto-couplers. When this is done the MTO feature is “muted” and control of the output PWM stage is under control of the digital control core. If not using the MTO feature, these connections must be made in order for the Xenus to be enabled.

FUNCTIONAL DIAGRAM

J5 SIGNALS

MOTOR TORQUE OFF (MTO)

MTO CONNECTOR MUTING CONNECTIONS

These connections MUST be made to enable the Xenus.

Pulse

Direction

[IN5]

[IN6]

CU

CD

[IN5]

[IN6]

CU (Count-Up)

CD (Count-Down)

Enc. A

Enc. B

IN4(14)

IN5(15)

Encoder ph. B

Encoder ph. A

PULSE

DIRECTION

[IN3+]

[IN4-]

[IN5+]

[IN6-]

CD (Count-Down)

CU (Count-Up)

PULSE

DIRECTION

[IN3+]

[IN4-]

[IN5+]

[IN6-]

Enc. B

Enc A

[IN5+]

[IN6-]

Encoder ph. A

[IN3+]

[IN4-]

Encoder ph. B

Duty = 0~100% Current orVelocity

Polarity orDirection

[IN5]

[IN6]

Current orVelocity

No function

[IN5]

[IN6]

Duty = 50% ±50%

<no connection>

Duty = 0 - 100%PWM

Direction

[IN3+]

[IN4-]

[IN5+]

[IN6-]

Current orVelocity

[IN3+]

[IN4-]

Duty = 50% ±50%

NoFunction<no connection>

[IN5+]

[IN6-]


Xenus PLUS

EtherCAT XELCOMMAND INPUTS

DIGITAL POSITIONDigital position commands can be in either single-ended or differential format. Single-ended signals should be sourced from devices with active pull-up and pull-down to take advantage of the high-speed inputs. Differential inputs have 121 Ω line-terminators.

DIGITAL TORQUE, VELOCITYDigital torque or velocity commands can be in either single-ended or differential format. Single-ended signals must be sourced from devices with active pull-up and pull-down to take advantage of the high-speed inputs.

SINGLE-ENDED PWM & DIRECTION

SINGLE-ENDED 50% PWM DIFFERENTIAL 50% PWM

DIFFERENTIAL PWM & DIRECTION

SINGLE-ENDED PULSE & DIRECTION

SINGLE-ENDED CU/CD

QUAD A/B ENCODER SINGLE-ENDED

DIFFERENTIAL CU/CD

DIFFERENTIAL PULSE & DIRECTION

QUAD A/B ENCODER DIFFERENTIAL

SecondaryEncoder Input

Input/OutputSelect

Quad A/B/X primaryencoder

MAX3032

MAX3097

Buffered A/B/X signalsfrom primary encoder


Input/OutputSelect

MAX3362

MAX3097

Emulated Quad A/Bsignals from analog Sin/Cos encoder

Emulated A/B signals

Input/OutputSelect

MAX3097

MAX3032

A/B/X signals fromdigital encoder

Input/OutputSelect

MAX3097

MAX3032

Pulse/Dir or CU/CD differential commands


Xenus PLUS

EtherCAT XELThis port consists of three differential input/output channels that take their functions from the Basic Setup of the drive.With quad A/B encoder feedback, the port works as an output, buffering the signals from the encoder. With resolver or sin/cos encoder versions, the feedback is converted to “emulated” quad A/B/X signals with programmable resolution. These signals can then be fed back to an external motion controller that closes the position or velocity loops. As an input, the port can take quad A/B signals to produce a dual-loop position control system or use the signals as master-encoder commands in camming mode. In addition, the port can take stepper command signals (CU/CD or Pulse/Direction) in differential format.

AS BUFFERED OUTPUTS FROM A DIGITAL QUADRATURE PRIMARY ENCODERWhen using a digital quadrature feedback encoder, the A/B/X signals drive the multi-mode port output buffers directly. This is useful in systems that use external controllers that also need the motor feedback encoder signals because these now come from J8, the Control connector. In addition to eliminating “Y” cabling where the motor feedback cable has to split to connect to both controller and motor, the buffered outputs reduce loading on the feedback cable that could occur if the motor encoder had to drive two differential inputs in parallel, each with it’s own 121 ohm terminating resistor.

AS EMULATED QUAD A/B/X ENCODER OUTPUTS FROM AN ANALOG SIN/COS FEEDBACK ENCODERAnalog sin/cos signals are interpolated in the drive with programmable resolution. The incremental position data is then converted back into digital quadrature format which drives the multi-mode port output buffers. Some analog encoders also produce a digital index pulse which is connected directly to the port’s output buffer. The result is digital quadrature A/B/X signals that can be used as feedback to an external control system.

AS A MASTER OR CAMMING ENCODER INPUT FROM A DIGITAL QUADRATURE ENCODERWhen operating in position mode the multi-mode port can accept digital command signals from external encoders. These can be used to drive cam tables, or as master-encoder signals when operating in a master/slave configuration.

AS DIGITAL COMMAND INPUTS IN PULSE/DIRECTION,PULSE-UP/PULSE-DOWN, OR DIGITAL QUADRATURE ENCODER FORMATThe multi-mode port can also be used when digital command signals are in a differential format. These are the signals that typically go to single-ended inputs. But, at higher frequencies these are likely to be differential signals in which case the multi-mode port can be used.

MULTI-MODE ENCODER PORT

AS COMMAND INPUTS

AS AN OUTPUT FOR FEEDBACK SIGNALS TO AN EXTERNAL CONTROLLER

+

12V+

100 pF

2.5V

MAX3096

MAX3096

MAX3096

MAX3096

[IN3]

J8 Control

100 pF

1k

[IN4]

10k

100 pF

10k

[IN5]

100 pF[IN6]

+5V

10k

+5V

1k

+

10k

+5V

1k

2.5V

1k

+5V

6

7

8

10

100p

10k

10k 74HC14[IN1]

[IN2][IN15]

A

+5.0 V

12V+

100 pF

MAX3096

MAX3096

10k

[IN3]

100 pF

1k

[IN4]

+5V

100 pF

10k

[IN5]

100 pF[IN6]

+5V

10k

61k

+5V

1k

1k

+5V

10k

7

8

10

J8 Control


Xenus PLUS

EtherCAT XELCOMMAND INPUTS

DIGITAL INPUTS [IN3~6]These inputs have all the programmable functions of the GP inputs plus these additional functions on [IN8] & [IN9] which can be configured as single-ended or differential:

• PWM 50%, PWM & Direction for Velocity or Current modes• Pulse/Direction, CU/CD, or A/B Quad encoder inputs for Position or Camming modes

DIFFERENTIALSINGLE-ENDED12 Vdc max 12 Vdc max

NON-ISOLATED DIGITAL INPUTSInputs [IN1,2,15] are 24V tolerant These are high-speed types with pull-up resistors to +5 Vdc and 1 µs RC filters when driven by active sources. The active level is programmable on each input. Input [IN1] is dedicated to the drive enable function. The remaining inputs [IN2~IN15] have programmable functions.

HS Inputs [IN1,2,15]24 Vdc max

PLC outputs are frequently current-sourcing from 24V for driving grounded loads. PC based digital controllers commonly use NPN or current-sinking outputs. Set the Xenus inputs to pull-down to ground for current-sourcing connections, and to pull-up to 5V for current-sinking connections.

2

3

15

1

+

1.5V

5.36k

Frame Ground

AIN1+

AIN2+

AIN1-

AIN2-

Vref

J8D/A

F.G.

±10V

Sgnd

-

11

12

19

+

1.5V

5.36k Vref

Sgnd

-

J9

+24V

24V GND

4.99k 5.1V

[IN7] 4.7k

4.7k

4.7k

4.7k

[COMM_A]2

3

4.99k 5.1V

[IN8]

4

4.99k 5.1V

[IN9]

5

4.99k 5.1V

[IN10]

6+

24V

J9

+24V

24V GND

4.99k 5.1V

[IN11] 4.7k

4.7k

4.7k

4.7k

[COMM_B]7

8

4.99k 5.1V

[IN12]

9

4.99k 5.1V

[IN13]

10

4.99k 5.1V

[IN14]

11+

24V


Xenus PLUS

EtherCAT XEL

ANALOG INPUTSTwo differential analog inputs with ±10 Vdc range have programmable functions. As a reference input [AIN1] can take position/velocity/torque commands from a controller. A second input [AIN2] is programmable for other functions. The ratio of drive output current or velocity vs. reference input voltage is programmable.

OPTO-ISOLATED DIGITAL INPUTSThese inputs have all the programmable functions of the GP inputs plus opto-isolation. There are two groups of four inputs, each with its’ own common terminal. Grounding the common terminal configures the inputs to work with current-sourcing outputs from controllers like PLC’s. When the common terminal is connected to +24V, then the inputs will be activated by current-sinking devices such as NPN transistors or N-channel MOSFETs. The minimum ON threshold of the inputs is ±15 Vdc.

[IN11~14][IN7~10]±30 Vdc max ±30 Vdc max

Inputs [7~14] work with current-sourcing OR current-sinking connections. Connect the COMM to controller ground/common for current-sourcing connections and to 15~24V from the controller for current-sinking connections.

J9

[OUT4+]

[OUT4-]

+20mA

30V maxR-L

+20mA

30V maxR-L

14

15

[OUT5+]12

13[OUT5-]

100mA

100mA

+30V max

+

R-L

R-L

16

17

15

+5V

+5V

[OUT1]

Sgnd

[OUT2]

J8

1009

15

J8

J8

NC7SZ125

+5V

18

15

[OUT3]

Sgnd±32mA

R

+

J4

3+24V

Brk

0V

2

1

24V

BRK


Xenus PLUS

EtherCAT XELOUTPUTS

DIGITAL OUTPUTS [OUT1], [OUT2]These are open-drain MOSFETs with 1 kΩ pull-up resistors in series with a diode to +5 Vdc. They can sink up to 1 Adc from external loads operating from power supplies to +30 Vdc. The output functions are programmable. The active state of the outputs is programmable to be on or off. When driving inductive loads such as a relay, an external fly-back diode is required. The internal diode in the output is for driving PLC inputs that are opto-isolated and connected to +24 Vdc. The diode prevents conduction from +24 Vdc through the 1 kΩ resistor to +5 Vdc in the drive. This could turn the PLC input on, giving a false indication of the drive output state.

ANALOG OUTPUTThe analog output is programmable and has an output voltage range of ±5 Vdc. An op-amp buffers the output of a 12-bit D/A converter.

HIGH SPEED OUTPUT [OUT3]5V CMOS

OPTO-ISOLATED OUTPUTS [OUT4,5]30 Vdc max Zener clamping diodes across outputs allow driving of resistive-inductive (R-L) loads without external flyback diodes.

BRAKE OUTPUT [OUT6]This output is an open-drain MOSFET with an internal flyback diode connected to the +24 Vdc input. It can sink up to 1A from a motor brake connected to the +24 Vdc supply. The operation of the brake is programmable with CME 2. It can also be programmed as a general-purpose digital output.

+5V output @ 400 mA

Signal Ground

21

20

17

5

19Sin(+)

Sin(-)

Cos(+)

Cos(-)

Inx(+)

Inx(-)

18

1

-

+

-

+

10k

121

J10

10k

121

Encoder

FG

sin

cos

+5V

0V

23

22

-

+10k

121indx

Frame Ground

10k

Sin

Cos

Indx

10k

10k

Encoder

FG Frame Ground

J10

MAX3097

Enc. A121A13

12

1

MAX3097

Enc. B121B11

10

MAX3097

Enc. Index121Z9

8/X

X

/B

B

/A

A

+5V

0V

+5V output @ 400 mA

Signal Ground

6

5

Resolver

FG Frame Ground

J10

Sin(+)

Sin(-)

Cos(-)

Cos(+)

Ref(+)

Ref(-)

21

20

19

18

1

23

22

R/DConversionSinS3 S1

S2

S4

R1R2

Cos

Ref

MAX3097

MAX3097

MAX3097

Enc. A

Enc. B

Enc. Index

A

/A

B

/B

X

/X

EncoderXenus Plus

121

121

121

FG Frame Ground

J10

A

B

+5V

0V

+5V Out2 @ 400 mA

Signal Ground

13

12

1

11

10

9

8

16

17 6

5 25 26

QUAD A/B ENCODER WITH FAULT PROTECTIONEncoders with differential line-driver outputs provide incremental position feedback via the A/B signals and the optional index signal (X) gives a once per revolution position mark. The MAX3097 receiver has differential inputs with fault protections for the following conditions:Short-circuits line-line: This produces a near-zero voltage between A & /A which is below the differential fault threshold.Open-circuit condition: The 121Ω terminator resistor will pull the inputs together if either side (or both) is open.

This will produce the same fault condition as a short-circuit across the inputs.Low differential voltage detection: This is possible with very long cable runs and a fault will occur if the differential input voltage is < 200mV.±15kV ESD protection: The 3097E has protection against high-voltage discharges using the Human Body Model.Extended common-mode range: A fault occurs if the input common-mode voltage is outside of the range of -10V to +13.2V

ANALOG SIN/COS INCREMENTAL ENCODERThe sin/cos/index inputs are differential with 121 Ω terminating resistors and accept 1 Vp-p signals in the format used by incremental encoders with analog outputs, or with ServoTube motors.

RESOLVER (-R MODELS)Connections to the resolver should be made with shielded cable that uses three twisted-pairs. Once connected, resolver set up, motor phasing, and other commissioning adjustments are made with CME 2 software. There are no hardware adjustments.

CONNECTIONS WITH A/B/X ENCODER CONNECTIONS WITH NO INDEX SIGNAL


Xenus PLUS

EtherCAT XELMOTOR CONNECTIONSMotor connections are of three types: phase, feedback, and thermal sensor. The phase connections carry the drive output currents that drive the motor to produce motion. A thermal sensor that indicates motor overtemperature is used to shut down the drive to protect the motor. Feedback can be digital quad A/B encoder, analog sin/cos encoder, resolver or digital Halls, depending on the version of the drive.

-

+

-

+

A

B

A

B

EncoderXenus Plus

121

Sin(+)

Sin(-)

Cos(+)

Cos(-)

Dat

/Dat

Clk

/Clk121

FG Frame Ground

J10

Clk

DataMAX3362B

MAX3362B

Data

Clk9

8

1

15

14

+5V

0V

+5V output @ 400 mA

Signal Ground

6

21

20

10k

10k

121 Sin

Cos

10k

10k

121

sin

cos

19

18

5

Encoder

121

121

Clk

/Clk

Dat

/Dat

FG Frame Ground

J10

Clk

DataMAX3362B

MAX3362B

Data

Clk

+5V

0V

+5V output @ 400 mA

A

A

B

B

Signal Ground

9

8

1

15

14

6

5

BiSSEncoder

Xenus

121

121

MA+

MA-

SL+

SL-

FG Frame Ground

J10

Clk

DataMAX3362B

MAX3362B

Master

Slave

V+

V-

+5V output @ 400 mA

Signal Ground

9

8

1

15

14

6

5

Nikon-AEncoder

Xenus

121

1.2k

1.2k

220

5V

SD+

SD-

0V

+5V

J10

1

15

14

V+

V-

5V output

Signal Ground

6

5

Cmd

D-R

SD

MAX3362B

Cmd

D-R

SD

MAX3362B


Xenus PLUS

EtherCAT XELMOTOR CONNECTIONS (CONT’D)

SSI ABSOLUTE ENCODERThe SSI (Synchronous Serial Interface) is an interface used to connect an absolute position encoder to a motion controller or control system. The XEL drive provides a train of clock signals in differential format to the encoder which initiates the transmission of the position data on the subsequent clock pulses. The polling of the encoder data occurs at the current loop frequency (16 kHz). The number of encoder data bits and counts per motor revolution are programmable. The hardware bus consists of two signals: SCLK and SDATA. Data is sent in 8 bit bytes, LSB first. The SCLK signal is only active during transfers. Data is clocked out on the falling edge and clock in on the rising edge of the Master.

ENDAT ABSOLUTE ENCODERThe EnDat interface is a Heidenhain interface that is similar to SSI in the use of clock and data signals, but which also supports analog sin/cos channels from the same encoder. The number of position data bits is programmable as is the use of sin/cos channels. Use of sin/cos incremental signals is optional in the EnDat specification.

BiSS ABSOLUTE ENCODERBiSS is an - Open Source - digital interface for sensors and actuators. BiSS refers to principles of well known industrial standards for Serial Synchronous Interfaces like SSI, AS-Interface® and Interbus® with additional options. Serial Synchronous Data Communication Cyclic at high speed 2 unidirectional lines Clock and Data Line delay compensation for high speed data transfer Request for data generation at slaves Safety capable: CRC, Errors, Warnings Bus capability incl. actuators Bidirectional BiSS B-protocol: Mode choice at each cycle start BiSS C-protocol: Continuous mode

NIKON-A ABSOLUTE ENCODERThe Nikon A interface is a serial, half-duplex type that is electrically the same as RS-485

Halls

+5V output @ 400 mA

* Signal Ground

+5V

0V

6

5

10K

100p

10KHall U+5V

J10

2

100p

10K

10KHall V

+5V

3

100p

10K

10KHall W

+5V

4

Hall A

Hall B

Hall C

* Alternate Sgnd connections on J10 are pins 16, 25, 26

J2

1F.G.PWM

+HV

0V

+

W

V

U

2

3

4

Motor3 ph.

7

5 16 25 26

+5V

Motemp[AIN3]

Thermistor,Posistor,

or switch

Signal Gnd

4.99k

100k

150k

100n

J10


Xenus PLUS


MOTOR PHASE CONNECTIONSThe drive output is a three-phase PWM inverter that converts the DC buss voltage (+HV) into three sinusoidal voltage waveforms that drive the motor phase-coils. Cable should be sized for the continuous current rating of the motor. Motor cabling should use twisted, shielded conductors for CE compliance, and to minimize PWM noise coupling into other circuits. The motor cable shield should connect to motor frame and the drive frame ground terminal (J2-1) for best results.

DIGITAL HALL SIGNALSHall signals are single-ended signals that provide absolute feedback within one electrical cycle of the motor. There are three of them (U, V, & W) and they may be sourced by magnetic sensors in the motor, or by encoders that have Hall tracks as part of the encoder disc. They typically operate at much lower frequencies than the motor encoder signals, and are used for commutation-initialization after startup, and for checking the motor phasing after the amplifier has switched to sinusoidal commutation.

MOTOR TEMPERATURE SENSORAnalog input [AIN3] Motemp, is for use with a motor overtemperature switch or sensor. The input voltage goes through a low-pass filter to a 12-bit A/D converter. The active level of the input, Vset, is programmable generate an over-temperature fault if the input voltage is <Vset, or >Vset.


Input/OutputSelect

Quad A/B/X primaryencoder

MAX3032

MAX3097

Buffered A/B/X signalsfrom primary encoder


Input/OutputSelect

MAX3362

MAX3097

Emulated Quad A/Bsignals from analog Sin/Cos encoder

Emulated A/B signals

Input/OutputSelect

MAX3097

MAX3032

A/B/X signals fromdigital encoder

Input/OutputSelect

MAX3097

MAX3032

Pulse/Dir or CU/CD differential commands


Xenus PLUS


MULTI-MODE ENCODER PORTThis port consists of three differential input/output channels that take their functions from the Basic Setup of the drive.With quad A/B encoder feedback, the port works as an output, buffering the signals from the encoder. With resolver or sin/cos encoder versions, the feedback is converted to “emulated” quad A/B/X signals with programmable resolution. These signals can then be fed back to an external motion controller that closes the position or velocity loops. As an input, the port can take quad A/B signals to produce a dual-loop position control system or use the signals as master-encoder commands in camming mode. In addition, the port can take stepper command signals (CU/CD or Pulse/Direction) in differential format.

AS BUFFERED OUTPUTS FROM A DIGITAL QUADRATURE PRIMARY ENCODERWhen using a digital quadrature feedback encoder, the A/B/X signals drive the multi-mode port output buffers directly. This is useful in systems that use external controllers that also need the motor feedback encoder signals because these now come from J8, the Control connector. In addition to eliminating “Y” cabling where the motor feedback cable has to split to connect to both controller and motor, the buffered outputs reduce loading on the feedback cable that could occur if the motor encoder had to drive two differential inputs in parallel, each with it’s own 121 ohm terminating resistor.

AS EMULATED QUAD A/B/X ENCODER OUTPUTS FROM AN ANALOG SIN/COS FEEDBACK ENCODERAnalog sin/cos signals are interpolated in the drive with programmable resolution. The incremental position data is then converted back into digital quadrature format which drives the multi-mode port output buffers. Some analog encoders also produce a digital index pulse which is connected directly to the port’s output buffer. The result is digital quadrature A/B/X signals that can be used as feedback to an external control system.

AS A MASTER OR CAMMING ENCODER INPUT FROM A DIGITAL QUADRATURE ENCODERWhen operating in position mode the multi-mode port can accept digital command signals from external encoders. These can be used to drive cam tables, or as master-encoder signals when operating in a master/slave configuration. See page 13 for connections when A/B encoders with no X index signal are used.

AS DIGITAL COMMAND INPUTS IN PULSE/DIRECTION,PULSE-UP/PULSE-DOWN, OR DIGITAL QUADRATURE ENCODER FORMATThe multi-mode port can also be used when digital command signals are in a differential format. These are the signals that typically go to single-ended inputs. But, at higher frequencies these are likely to be differential signals in which case the multi-mode port can be used.

S

/S 13

14

15 [OUT4-] GPI

J9

4

3

2

8

7

1

6

5

F.G.

[IN8] GPI

[COMM_A]

[IN7] GPI

[COMM_B]

[IN10] GPI

[IN9] GPI

12

11

10

9

14

13

[IN12] GPI

[OUT5+] GPI

[IN13] GPI

[IN14] GPI

[OUT4+] GPI

[OUT5-] GPI

[IN11] GPI

Multi-ModeEncoder

Port

Frame Ground

A

/A

B

/B

X

/X

FrameGnd

Outputs BufferedQuad A/B fromEncoder

Sgnd 25

24

+5V Out2

6

A

B

/B

X

/X

/A

21

22

23

26

24

25

1

8

9

10

11

12

1

13

Hall W 4

Hall V 3

Hall U 2

5

26

Signal Ground

Signal Ground

Signal Ground

16

+5V Out2 17

DIGITALENCODER

DIGITALHALLS

/A

A

/B

B

/X

Vcc

0V

FLT

X

+5V Out1

Signal Ground

Ain1(-)

Ain1(+)±10 VdcAnalog

Reference

AC MAINS:100 to 240 Vac1Ø or 3Ø47 to 63 Hz

L3

L2

L1

Fuse

1

H

NLIN

EFI

LTER

BRUSHLESSMOTOR

DANGER: HIGH VOLTAGECIRCUITS ON J1, J2, & J3ARE CONNECTED TOMAINS POWER

* Fuse

* Fuse

Earth

* Fuse

* Fuse

* Optional

J3REGEN+

REGEN-

Frame Ground

U

V

W

1

4

5

2

3

4

3

2

1

Mot U

Mot V

Mot W

Frame Ground

J4

J1

J2

J8

+24V

BRAKE

RTN

Signal Ground

Aout

[OUT2]

[OUT1]

[OUT3] HS

L3

L2

L1

BRAKE

Required forDrive Operation

Control Power Supply

+24 Vdc0.5 Adc

7

12

11

2

3

1

15

10

8

9

17

16

18

Frame Grounding Tab

[IN1] Enable

[IN4] HS

[IN2] GP

[IN3] HS

Ain2(-)

Ain2(+)

[IN6] HS

[IN5] HS

6

5

4

J1020

19

2

3

4

3

2

1

+

-

Motemp [AIN3]

TEMPSENSOR7

[IN15](NOTE 1)

(NOTE 1)


Xenus PLUS

EtherCAT XELQuad A/B Encoder

NOTES:1) +5V Out1 and Out2 are independent power supplies and each is rated for 400 mA2) Line filter is required for CE3) Active signals in Multi-Mode port depend on drive configuration. All are shown for completeness.

MOTOR CONNECTIONS (CONT’D)

= Shielded cables required for CE compliance

S

/S 13

14

15 [OUT4-] GPI

J9

4

3

2

8

7

1

6

5

F.G.

[IN8] GPI

[COMM_A]

[IN7] GPI

[COMM_B]

[IN10] GPI

[IN9] GPI

12

11

10

9

14

13

[IN12] GPI

[OUT5+] GPI

[IN13] GPI

[IN14] GPI

[OUT4+] GPI

[OUT5-] GPI

[IN11] GPI

Multi-ModeEncoder

Port

Frame Ground

A

/A

B

/B

X

/X

FrameGnd

Outputs EmulatedQuad A/B fromAnalog Encoder

Sgnd 25

24

+5V Out2 6

Sin(+)

Cos(+)

Cos(-)

Inx(+)

Inx(-)

Sin(-)

21

22

23

26

24

25

1

22

23

20

21

18

1

19

Hall W 4

Hall V 3

Hall U 2

Signal Ground 5

Signal Ground 16

Signal Ground 26

+5V Out2 17

Sin / CosENCODER

DIGITALHALLS

Sin(-)

Sin(+)

Cos(-)

Cos(+)

Index(-)

Vcc

0V

FLT

Index(+)

+5V Out1

Signal Ground

Ain1(-)


Reference

7Motemp

[AIN3]

TEMPSENSOR


L3

L2

L1

Fuse

1

H

NLIN

EFI

LTER

BRUSHLESSMOTOR


* Fuse

* Fuse

Earth

* Fuse

* Fuse

* Optional

J3REGEN+

REGEN-

Frame Ground

U

V

W

1

4

5

2

3

4

3

2

1

Mot U

Mot V

Mot W

Frame Ground

J4

J1

J2

J8

+24V

BRAKE

RTN

Signal Ground

Aout

[OUT2]

[OUT1]

[OUT3] HS

L3

L2

L1

BRAKE



+24 Vdc0.5 Adc

7

12

11

2

3

1

15

10

8

9

17

16

18

Frame Grounding Tab

[IN1] Enable

[IN4] HS

[IN2] GP

[IN3] HS

Ain2(-)

Ain2(+)

[IN6] HS

[IN5] HS

6

5

4

J1020

19

2

3

4

3

2

1

+

-

[IN15]


Xenus PLUS

EtherCAT XELSin/Cos Encoder




(NOTE 1)

(NOTE 1)

15 [OUT4-] GPI

J9

4

3

2

8

7

1

6

5

F.G.

[IN8] GPI

[COMM_A]

[IN7] GPI

[COMM_B]

[IN10] GPI

[IN9] GPI

12

11

10

9

14

13

[IN12] GPI

[OUT5+] GPI

[IN13] GPI

[IN14] GPI

[OUT4+] GPI

[OUT5-] GPI

[IN11] GPI

Multi-ModeEncoder

Port

Frame Ground

A

/A

B

/B

X

/X

S

/S

FrameGnd

Outputs EmulatedQuad A/B fromResolver

Sgnd 25

24

+5V Out2 6

Sin(+)

Cos(+)

Cos(-)

Ref(+)

Ref(-)

Sin(-)

21

22

23

26

24

25

1

22

23

20

21

18

1

19

Hall W 4

Hall V 3

Hall U 2

Signal Ground 16

Signal Ground 26

Signal Ground 5

+5V Out2 17

Resolver

S1 Sin(-)

S3 Sin(+)

S4 Cos(-)

S2 Cos(+)

R2 Ref(-)

R1 Ref(+)

+5V Out1

Signal Ground

Ain1(-)


Reference

7Motemp

[AIN3]

TEMPSENSOR


L3

L2

L1

Fuse

1

H

NLIN

EFI

LTER

BRUSHLESSMOTOR


* Fuse

* Fuse

Earth

* Fuse

* Fuse

* Optional

J3REGEN+

REGEN-

Frame Ground

U

V

W

1

4

5

2

3

4

3

2

1

Mot U

Mot V

Mot W

Frame Ground

J4

J1

J2

J8

+24V

BRAKE

RTN

Signal Ground

Aout

[OUT2]

[OUT1]

[OUT3] HS

L3

L2

L1

BRAKE



+24 Vdc0.5 Adc

7

12

11

2

3

1

15

10

8

9

17

16

18

Frame Grounding Tab

[IN1] Enable

[IN4] HS

[IN2] GP

[IN3] HS

Ain2(-)

Ain2(+)

[IN6] HS

[IN5] HS

6

5

4

J1020

19

2

3

4

3

2

1

+

-

[IN15]

13

14


Xenus PLUS

EtherCAT XELResolver



(NOTE 1)

(NOTE 1)


Signal Pin

Motor Phase U 4

Motor Phase V 3

Motor Phase W 2

Cable Shield 1

Signal Pin

Mains Input L3 4

Protective Ground 3

Mains Input L2 2

Mains Input L1 1

Signal Pin

Regen Resistor 1

No Connection 2

Regen Resistor 3

No Connection 4

Cable Shield 5

Signal Pin

+24 Vdc Control Power 3

Brake Output [OUT6] 2

0V (+24 Vdc Return) 1

J1 MAINS CONNECTIONS

J2 MOTOR OUTPUTS

J3 REGEN RESISTOR

J4 +24 VDC & BRAKE

J1 CABLE CONNECTOR: Wago: 51118287 or 721-204/026-045/RN01-0000

Euro-style 7,5 mm pluggable female terminal block with preceding ground receptacle

Cable: AWG 12, 600 V recommended for XEL-230-36-R and XEL-230-40-R models, AWG 14, 600V for XEL-230-18-R Shielded cable required for CE compliance

J2 CABLE CONNECTOR: Wago: 51118008 or 721-104/026-047/RN01-0000

Euro-style 5,0 mm pluggable female terminal blockCable: AWG 12, 600 V recommended

for XEL-230-36-R and XEL-230-40-R models, AWG 14, 600V for XEL-230-18-R Shielded cable required for CE compliance

J3 CABLE CONNECTOR:Wago: 51111279 or 721-605/000-044/RN01-0000

Euro-style 5,0 mm pluggable male terminal blockCable: AWG 12, 600 V recommended


WARNING: Hazardous voltages exist on connections to J1, J2, & J3 when power is applied, and for up to 30 seconds after power is removed.

WIRE INSERTION/EXTRACTION TOOL:Used on J1, J2, J3, & J4

Wago 231-131 ISOLATED CIRCUIT

ISOLATED CIRCUIT

J4 CABLE CONNECTOR:Wago: 51117974 or 721-103/026-047/RN01-0000

Euro-style 5,0 mm pluggable terminal block

NOTE: AN EXTERNAL +24 VDC POWER SUPPLY IS REQUIRED FOR OPERATION

J1

J2

J3

J4

J5


Xenus PLUS

EtherCAT XELQuad A/B & Sin/Cos Encoder


9 [AOUT] 18 [OUT3] HS PIN SIGNAL

8 [IN5] HS 17 [OUT2] 26 Multi Enc A

7 [IN4] HS 16 [OUT1] 25 Multi Enc /A

6 [IN3] HS 15 Signal Gnd 24 Multi Enc B

5 [IN2] GP 14 Multi Enc S 23 Multi Enc /B

4 [IN1] GP 13 Multi Enc /S 22 Multi Enc X

3 [AIN1-] 12 [AIN2-] 21 Multi Enc /X

2 [AIN1+] 11 [AIN2+] 20 +5V Out1

1 Frame Gnd 10 [IN6] HS 19 Signal Gnd

J8 CONTROL SIGNALS

PIN SIGNAL PIN SIGNAL PIN SIGNAL

1 Frame Gnd 6 [IN10] GPI 11 [IN14] GPI

2 [COMM_A] 7 [COMM_B] 12 [OUT5+] GPI

3 [IN7] GPI 8 [IN11] GPI 13 [OUT5-] GPI

4 [IN8] GPI 9 [IN12] GPI 14 [OUT4+] GPI


J9 SECONDARY I/O CONNECTOR



2 MTO-1(+) 7 MTO-LED(-)



5 MTO-2(-)


1 Frame Gnd 10 Enc /B 19 Sin(+)

2 Hall U 11 Enc B 20 Cos(-)

3 Hall V 12 Enc /A 21 Cos(+)

4 Hall W 13 Enc A 22 Index(-)

5 Signal Gnd 14 Enc /S 23 Index(+)

6 +5V Out2 15 Enc S 24 [IN15]

7 [AIN3] Motemp 16 Signal Gnd 25 Signal Gnd

8 Enc /X 17 +5V Out2 26 Signal Gnd

9 Enc X 18 Sin(-)


Xenus PLUS

EtherCAT XELQuad A/B & Sin/Cos Encoder

J5 SAFETY

J10 FEEDBACK

J10

J6

J7

J8

J9

J8 CABLE CONNECTOR:High-Density D-Sub female, 26 Position

J9 CABLE CONNECTOR:High-Density D-Sub male, 15 Position


J5 CABLE CONNECTOR:D-Sub male, 9 Position

Signal Pin

Motor Phase U 4

Motor Phase V 3

Motor Phase W 2

Cable Shield 1

Signal Pin

Mains Input L3 4

Protective Ground 3

Mains Input L2 2

Mains Input L1 1

Signal Pin

Regen Resistor 1

No Connection 2

Regen Resistor 3

No Connection 4

Cable Shield 5

Signal Pin

+24 Vdc Control Power 3

Brake Output [OUT6] 2

0V (+24 Vdc Return) 1


Xenus PLUS


J1 MAINS CONNECTIONS

J2 MOTOR OUTPUTS

J3 REGEN RESISTOR

J4 +24 VDC & BRAKE

J1 CABLE CONNECTOR: Wago: 51118287 or 721-204/026-045

Euro-style 7,5 mm pluggable female terminal block with preceding ground receptacle

Cable: AWG 12, 600 V recommended for XEL-230-36-R and XEL-230-40-R models, AWG 14, 600V for XEL-230-18-R Shielded cable required for CE compliance

J2 CABLE CONNECTOR: Wago: 51118008 or 721-104/026-047

Euro-style 5,0 mm pluggable female terminal blockCable: AWG 12, 600 V recommended


J3 CABLE CONNECTOR:Wago: 51111279 or 721-605/000-044

Euro-style 5,0 mm pluggable male terminal blockCable: AWG 12, 600 V recommended


WARNING: Hazardous voltages exist on connections to J1, J2, & J3 when power is applied, and for up to 30 seconds after power is removed.

WIRE INSERTION/EXTRACTION TOOL:Used on J1, J2, J3, & J4

Wago 231-131 ISOLATED CIRCUIT

ISOLATED CIRCUIT

J4 CABLE CONNECTOR:Wago: 51117974 or 721-103/026-047

Euro-style 5,0 mm pluggable terminal block

NOTE: AN EXTERNAL +24 VDC POWER SUPPLY IS REQUIRED FOR OPERATION

J1

J2

J3

J4

J5


1 Frame Gnd 6 [IN10] GPI 11 [IN14] GPI

2 [COMM_A] 7 [COMM_B] 12 [OUT5+] GPI


4 [IN8] GPI 9 [IN12] GPI 14 [OUT4+] GPI


J9 SECONDARY I/O CONNECTOR


9 [AOUT] 18 [OUT3] HS PIN SIGNAL

8 [IN5] HS 17 [OUT2] 26 Multi Enc A

7 [IN4] HS 16 [OUT1] 25 Multi Enc /A

6 [IN3] HS 15 Signal Gnd 24 Multi Enc B

5 [IN2] GP 14 Multi Enc S 23 Multi Enc /B

4 [IN1] GP 13 Multi Enc /S 22 Multi Enc X

3 [AIN1-] 12 [AIN2-] 21 Multi Enc /X

2 [AIN1+] 11 [AIN2+] 20 +5V Out1

1 Frame Gnd 10 [IN6] HS 19 Signal Gnd

J8 CONTROL SIGNALS



2 MTO-1(+) 7 MTO-LED(-)



5 MTO-2(-)


1 Frame Gnd 10 Enc /B 19 Sin1(+) S3

2 Hall U 11 Enc B 20 Cos1(-) S4

3 Hall V 12 Enc /A 21 Cos1(+) S2

4 Hall W 13 Enc A 22 Ref(-) R2

5 Signal Gnd 14 Enc /S 23 Ref(+) R1

6 +5V Out2 15 Enc S 24 [IN15]

7 [AIN3] Motemp 16 Signal Gnd 25 Signal Gnd

8 Enc /X 17 +5V Out2 26 Signal Gnd

9 Enc X 18 Sin1(-) S1


Xenus PLUS


J5 SAFETY

J10 FEEDBACK

J8 CABLE CONNECTOR:High-Density D-Sub female, 26 Position



J5 CABLE CONNECTOR:D-Sub male, 9 Position

J10

J6

J7

J8

J9

20

40

60

80

100

120

140

160

260240220200180160140120100

Energy Absorption vs.Mains Voltage

Mains Voltage (Vac)

Ener

gy

Abso

rption (

W·s

)

~

~ -

+

~+

REGEN(-) REGEN(+)

SHIELD

U

V

W

J2

DC BUS(+)

DC BUS(-)

J3

2350 µFL1

MAINSL3

L2J1

PWMSTAGE

POWERCONTROL

ISOLATION BARRIER

SHIELD

FEEDBACKPOWER &DECODING

J10

CONTROLLOGIC

+5 Vdc

ENABLE [IN1]

SIGNAL GND

CONTROLSIGNALGROUND

CONTROLSYSTEM

J8

GROUND+24 Vdc

+24VDC BRAKE

+24 VdcJ4

RTNCntrl

BRAKE

DC/DCConverter

&

POWER

LOGIC

SIGNAL

DC/DC

(SAFETY GROUND)

PWMINVERTER

MOTOR

FEEDBACK

CASE

FRAME GROUND

FRAME GROUND


Xenus PLUS

EtherCAT XEL

GROUNDINGA grounding system has three primary functions: safety, voltage-reference, and shielding. As a safety measure, the primary ground at J1-3 will carry fault-currents from the mains in the case of an internal failure or short-circuit of electronic components. Wiring to this is typically done with the green conductor with yellow stripe using the same gauge wire as that used for the mains. The pin on the drive at J1-3 is longer than the other pins on J1 giving it a first-make, last-break action so that the drive chassis is never ungrounded when the mains power is connected. This wire is a ‘bonding’ conductor that should connect to an earthed ground point and must not pass through any circuit interrupting devices.

All of the circuits on J1, J2, J3, and J4 are mains-connected and must never be grounded. The frame ground terminals at J1-3, J2-1, J3-5, J5-1, J8-1, J9-1, and J10-1 all connect to the drive chassis and are isolated from all drive internal circuits.Signal grounding references the drive control circuits to those of the control system. These controls circuits typically have their own earth connection at some point. To eliminate ground-loops it is recommended that the drive signal ground be connected to the control system circuit ground. When this is done the drive signal voltages will be referenced to the same 0 V level as the circuits in the control system. Small currents flow between controller and drive when inputs and outputs interact. The signal ground is the path for these currents to return to their power sources in both controller and drive.Shields on cables reduce emissions from the drive for CE compliance and protect internal circuits from interference due to external sources of electrical noise. Because of their smaller wire gauge, these should not be used as part of a safety-ground system. Motor cases can be safety-grounded either at the motor, by earthing the frame, or by a grounding conductor in the motor cable that connects to J2-1. This cable should be of the same gauge as the other motor phase cables.For CE compliance and operator safety, the drive heatplate should be earthed to the equipment frame. An unplated tab is provided on the heatplate (near to J1) for this connection.

DRIVE POWER SOURCESAn external +24 Vdc power supply is required, and powers an internal DC/DC converter that supplies all the control voltages for drive operation. Use of an external supply enables EtherCAT communication with the drive when the mains power has been removed.Power distribution in XEL is divided into three sections: +24 Vdc, signal, and high-voltage. Each is isolated from the other and all are isolated from the chassis.

EXTERNAL +24 VDCThe primary side of the DC/DC converter operates directly from the external +24 Vdc supply and is isolated from other drive power sections. The Brake output [OUT6] operates in this section and is referenced to the +24 Vdc return (0V). It sinks current from an external load connected to the external +24 Vdc power source.

INTERNAL SIGNAL POWERThe signal power section supplies power for the control circuits as well as logic inputs and outputs. Motor feedback signals such as Halls, encoder, and temperature sensor operate from this power source. All signal circuits are referenced to signal ground. This ground should connect to the control system circuit ground or common so that drive and controller inputs and output voltage levels work properly with each other.

MAINS POWERMains power drives the high-voltage section. It is rectified and capacitor-filtered to produce +HV which the PWM stage converts into voltages that drive either three phase brushless or DC brush motors. An internal solid-state switch together with an external power resistor provides dissipation during regeneration when the mechanical energy of the motor is converted back into electrical energy that must be dissipated before it charges the internal capacitors to an overvoltage condition. All the circuits in this section are “hot”, that is, they connect directly to the mains and must be considered high-voltages and a shock hazard requiring proper insulation techniques during installation.

REGENERATIONThe chart below shows the energy absorption in W·s for a Xenus Plus drive operating at some typical mains voltages. When the load mechanical energy is greater than these values an external regen resistor is available as an accessory.

Keep the chassis grounding connections short for best shielding performance

3 TURNSAROUNDTOROID

INDUCTOR

MOTOR

MAINS

REGEN

CONTROLLER

XENUSPlus

FEEDBACK

LINEFILTER

J1

J2

J10J8

J3J424 VPOWERSUPPLY

Uplated tab for heatplate

ground

Notes:1) Shielded cables required for CE are shown in the diagram above.2) Line filter required for CE3) Ferrite core (Magnetics Inc, ZW43615-TC) required for shielded

cable to regen resistor which must be in shielded enclosure.

Grounding and shielding are the means of controlling the emission of radio frequency energy from the drive so that it does not interfere with other electronic equipment.The use of shielded cables to connect the drive to motors and feedback devices is a way of extending the chassis of the drive out to these devices so that the conductors carrying noise generated by the drive are completely enclosed by a conductive shield.The process begins at the mains connector of the drive, J1. The ground terminal here has a circle around it indicating that this is the safety or “bonding” ground connection. This should be connected with wire that is the same gauge as that used for the mains. In the case of a short-circuit in the drive the function of this ground connection is to carry the fault current to earth ground until the safety device (fuse or circuit breakers) disconnects the drive from the mains. This connection ensures that the heatplate of the drive remains at earth potential and eliminating a shock hazard that could occur of the chassis were allowed to float to the potential of the mains.While this connection keeps the heatplate at earth potential the high frequency noise generated by switching circuits in the drive can radiate from the wire used for the safety ground connection. In order to keep the path between the heatplate and earth as short as possible it’s also recommended to mount the drive to the equipment panel. An unplated tab on the heatplate is provided for this and will ground the heatplate directly to the equipment frame, further reducing emissions.The heatplate also connects directly to the frame ground terminals on the motor, feedback, and regen connectors. Note that the ground symbols for these do not have a circle around them which indicates that these are for shielding and not not for safety grounding. Motors and their feedback devices (which are typically in the motor case) should be grounded by mounting to equipment that is grounded as a safety ground. By connecting the shields for these devices at the drive and at the device, the connection is continuous and provides a return path for radio-frequency energy to the drive.


Xenus PLUS

EtherCAT XELGROUNDING & SHIELDING FOR CE

Heatsink

#8-32 Mounting Screws

Dry Film Interface Pad

Xenus Plus Drive

Blue Protective Sheet (Discard)

Clear Protective Sheet (Discard)


Xenus PLUS

EtherCAT XELHEATSINK & FAN CONFIGURATIONS

HEATSINK MOUNTING

A dry-film interface pad is used in place of thermal grease. The pad is die-cut to shape and has holes for the heat sink mounting screws. There are two protective sheets, blue on one side and clear on the other. Both must be removed when the interface pad is installed.

STEPS TO INSTALL

1. Remove the blue protective sheet from one side of the pad and place the pad on the drive. Make sure that the holes in the pad align with the holes on the drive.

2. Remove the clear protective sheet from the pad.3. Mount the heatsink onto the drive taking care

to see that the holes in the heatsink, pad, and drive all line up.

4. Torque the #8-32 mounting screws to 16~20 lb-in (1.8~2.3 N·m).

NO HEATSINK NO FAN

NO HEATSINK WITH FAN

LOW-PROFILE HEATSINK NO FAN

LOW PROFILE HEATSINK WITH FAN

STANDARD HEATSINK NO FAN

STANDARD HEATSINK WITH FAN

NOTE: FANS ARE NOT INCLUDED WITH HEATSINKS OR HEATSINK KITS

20

30

40

50

60

2018161412108642

No Heatsink

StandardHeatsink

Low ProfileHeatsink w/fan

Low ProfileHeatsink orno Heatsink w/fan

StandardHeatsink w/fan

1

2

4

5

3

Mains: 120 Vac

Continuous Output Current (Adc)

Am

bie

nt

Tem

per

ature

(°C

)

3

1 2

4

5

20

30

40

50

60

20181614121086442

Mains: 240 Vac



No Heatsink

StandardHeatsink


4

5

1

2

3


Am

bie

nt

Tem

per

ature

(°C

)

1

2

3

4

5

20

30

40

50

60

121110987654321

StandardHeatsink




5

1

2

3

4

No Heatsink

Mains: 240 Vac


Am

bie

nt

Tem

per

ature

(°C

) 5

4

1

2

3

20

30

40

50

60

121110987654321

No Heatsink

StandardHeatsink




4

5

1

2

3

Am

bie

nt

Tem

per

ature

(°C

)

Mains: 120 Vac

1

3

4

5

2


20

30

40

50

60

654321

1

2

1

2

3 3

No Heatsink

Low ProfileHeatsink *

All other heatsink and fan combinations enable operation at 55 °C

Mains: 240 Vac


Am

bie

nt

Tem

per

ature

(°C

)

20

30

40

50

60

654321

Mains: 120 Vac

No Heatsink

Low ProfileHeatsink *

* All other heatsink and fan combinations enable operation at 55 °C


Am

bie

nt

Tem

per

ature

(°C

)

1

2

1

2


Xenus PLUS

EtherCAT XEL

XEL-230-18 XEL-230-18

XEL-230-36 XEL-230-36

XEL-230-40 XEL-230-40

The charts below show that maximum ambient temperature vs. continuous output current for the Xenus Plus models. The cooling options are no heatsink, standard heatsink, and low-profile heatsink. For each of these the drive can be operated with convection or forced-air cooling.

MAXIMUM OPERATING TEMPERATURE VS HEATSINK TYPE & AIR CIRCULATION

QTY REF DESCRIPTION MANUFACTURERS PART NUMBER

XEL-CK

Connector KitwithSolder Cup ConnectorsforJ5, J8, J9 & J10

1 J1 Plug, 4 position, 7.5 mm, female Wago: 721-204/026-045 (Note 1)


1 J3 Plug, 5 position, 5.0 mm, male Wago: 721-605/000-044 (Note 1)


4 J1~4 Tool, wire insertion & extraction (for J1~4) Wago: 231-131

1J5

Connector, D-Sub, 9-position, male, solder cup Norcomp: 171-009-103L001

1 Backshell, D-Sub, RoHS, metallized, for above Norcomp: 979-009-020R121

1J8

Connector, high-density D-Sub, 26 position, female, solder cup Norcomp: 180-026-203L001


1J9

Connector, high-density D-Sub, 15 position, male, solder cup Norcomp: 180-015-103L001


1J10

Connector, high-density D-Sub, 26 position, male, solder cup Norcomp: 180-026-103L001


SER-CK J5 RS-232 Cable Kit

XEL-NC-10 1 n/a EtherCAT network cable, 10 ft (3 m)

XEL-NC-01 1 n/a EtherCAT network cable, 1 ft (0.3 m)Note 1: For RoHS compliance, append “/RN01-0000” to the part numbers listed above

Heatsink Kits for Field Installation (Optional)

XEL-HL Heatsink Kit Low-Profile

1 Heatsink, low-profile

1 Heatsink thermal material

4 Heatsink hardware

XEL-HS Heatsink Kit Standard

1 Heatsink, standard

1 Heatsink thermal material

4 Heatsink hardware

Regeneration Resistors (Optional)

XTL-RA-03 Regeneration resistor assembly (for XEL-230-18), 30 Ω

XTL-RA-04 Regeneration resistor assembly (for XEL-230-36 & XEL-230-40 models), 15 Ω

Edge Filter (Optional)

XTL-FA-01 Edge filter

Edge Filter Connector Kit XTL-FK

1 Plug, 4 position, 5.0 mm, female Wago: 51118008 or 721-104/026-047/RN01-0000

1 Plug, 5 position, 5.0 mm, male Wago: 51111277 or 721-605/000-044/RN01-0000

2 Tool, wire insertion & extraction Wago: 231-131

ORDERING GUIDE

XEL-230-18 Xenus Plus EtherCAT Servo Drive 6/18 Adc




Xenus PLUS

EtherCAT XEL

Example: Order one Xenus Plus drive, resolver version, 6/18 A with solder-cup connector Kit, CME 2 CD, serial cable kit and small heatsink fitted at the factory:Qty Item Remarks 1 XEL-230-18-R-HS Xenus Plus servo drive 1 XEL-CK Connector Kit 1 CME 2 CME 2 CD 1 SER-CK Serial Cable Kit

Note: The heatsink can be fitted at the factory by adding an “-HS” or “-HL” to the drive part number to specify the standard or low-profile type. For fitting a heatsink to an drive in the field, complete kits are available (XEL-HS and XEL-HL). These kits contain the heatsink, mounting hardware, and dry-film interface.

Note: Specifications are subject to change without notice

ACCESSORIES

Add “-R” to model number for resolver option

EtherCAT is a registered trademark and patented technology, licensed by Beckhoff Automation GmbH, Germany.

xen pluseecat xel

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